Thin film transistor device and method of manufacturing the same

ABSTRACT

A polysilicon film is formed in a predetermined region on a glass substrate, and then a gate insulating film and a gate electrode, whose width is narrower than the gate insulating film, are formed thereon. Then, an interlayer insulating film and an ITO film are formed on an overall surface. Then, n-type source/drain regions having an LDD structure are formed by implanting the n-type impurity into the polysilicon film. Then, an n-type TFT forming region and a pixel-electrode forming region are covered with a resist film, and then p-type source/drain regions are formed by implanting the p-type impurity into the polysilicon film in a p-type TFT forming region. Then, the resist film is left only in the pixel-electrode forming region and the resist film is removed from other regions. A pixel electrode is formed by etching the ITO film while using the remaining resist film as a mask.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based upon and claims priority of JapanesePatent Application No. 2001-401483, filed in Dec. 28, 2001,the contentsbeing incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to a thin film transistor devicehaving thin film transistors (abbreviated as “TFTs” hereinafter) used ina liquid crystal display panel, an organic EL display panel, etc. and amethod of manufacturing the same.

[0004] 2. Description of the Prior Art

[0005] The liquid crystal display panel has such merits that such panelis thin and light in weight and the consumption power is small becausesuch panel can be driven by the low voltage, and is widely employed invarious electronic devices such as PDA (Personal Digital Assistant), thefinder of the video camera, and others. In particular, since theactive-matrix liquid crystal display panel, in which the switchingelement such as TFT or the like is provided to each pixel, is excellentin display quality to such an extent that it is equivalent to the CRT(Cathode Ray Tube), such display panel is employed in the display deviceof the television set, the personal computer, etc.

[0006] The normal TN (Twisted Nematic) liquid crystal display panel hasthe structure that the liquid crystal is sealed between two sheets oftransparent glass substrates. Out of two mutually-opposing surfaces(opposing surfaces) of these glass substrates, the black matrix, thecolor filters, the common electrode, etc. are formed on one surfaceside, and the TFTs, the pixel electrodes, etc. are formed on the othersurface side.

[0007] Also, the polarization plate is provided to the opposing surfacesand opposite surfaces of the glass substrates respectively. These twosheets of polarization plates are arranged such that the polarizationaxes of the polarization plates are set to intersect orthogonally witheach other, for example. According to this state, the display panel isset to the mode in which the light is transmitted when the electricfield is not applied and the light is shielded when the electric fieldis applied, i.e., the normally white mode. Also, if the polarizationaxes of two sheets of polarization plates are set in parallel with eachother, the display panel is set to the mode in which the light isshielded when the electric field is not applied and the light istransmitted when the electric field is applied, i.e., the normally blackmode. In the following explanation, the substrate on which the TFTs andthe pixel electrodes are formed is called the TFT substrate and thesubstrate on which the color filters and the common electrode are formedis called the CF substrate.

[0008] At present, the operating layer of TFT that is formed ofamorphous silicon is employed in the normal liquid crystal displaypanel. However, since the carrier mobility is small in the amorphoussilicon, there exists such a drawback that it is hard to apply suchoperating layer to the large and high-definition liquid crystal displaypanel. For this reason, the operating layer of TFT that is formed ofpolysilicon has been proposed, and such operating layer has already beenused practically in a part of products.

[0009] In such liquid crystal display panel, not only the TFTs formed inthe pixel portion (referred to as “pixel TFTs” hereinafter) but also theperipheral circuits such as the data driver, the gate driver, etc.,which are constructed by CMOS, etc., can be formed integrally on thesubstrate. Thus, there is the merit such that the production cost of theliquid crystal display panel can be considerably reduced. In this case,since the OFF current is large in the polysilicon TFT, the LDD (LightlyDoped Drain) structure must be employed in the pixel TFTs.

[0010]FIGS. 1A to 1L are sectional views showing a method ofmanufacturing a TFT substrate of the liquid crystal display panel in theprior art in order of step. In these Figures, for convenience ofexplanation, the pixel TFT (n-type TFT) is illustrated on the left sideand also the p-type TFT of the peripheral circuit is illustrated on theright side. Actually, the pixel TFTs are formed in the display regionand the peripheral circuit is formed on the outside of the displayregion. Also, since the n-type TFTs of the peripheral circuit can beformed similarly to the pixel TFTs, illustration and explanation of themwill be omitted herein.

[0011] First, as shown in FIG. 1A, a buffer layer 12 having adouble-layered structure consisting of a SiN film 12 a and a SiO₂ film12 b is formed on a glass substrate 11. Then, an amorphous silicon filmis formed on the SiO₂ film 12 b, and then the amorphous silicon ischanged into polysilicon by the annealing using the excimer laser toform a polysilicon film 13. Then, photoresist is coated on thepolysilicon film 13, and then photoresist films 14 each having apredetermined shape are formed by applying the exposing and developingprocesses to the photoresist.

[0012] Then, as shown in FIG. 1B, the polysilicon film 13 is etched byusing the photoresist films 14 as a mask and thus the polysilicon film13 is left only in the TFT forming region. Then, the photoresist films14 are removed.

[0013] Then, as shown in FIG. 1C, an insulating film 15 and a conductivefilm 16 are formed sequentially on an overall upper surface of the glasssubstrate 11. Then, as shown in FIG. 1D, gate electrodes 19 and gateinsulating films 18 are formed by etching the conductive film 16 and theinsulating film 15 by virtue of the photolithography method. At thistime, a width of the gate electrode 19 is formed slightly narrowlyrather than a width of the gate insulating film 18.

[0014] Then, as shown in FIG. 1E, source/drain regions of the n-type TFTare formed by ion-implanting P (phosphorus) into the polysilicon film13. For example, high-concentration impurity diffusion regions 13 b areformed by ion-implanting P into the polysilicon film 13 with a highconcentration at a low energy while using the gate insulating film 18and the gate electrode 19 as a mask. Also, LDD regions 13 a of then-type TFT are formed by ion-implanting P into the polysilicon film 13with a low concentration at a high energy while using the gate electrode19 as a mask.

[0015] Then, as shown in FIG. 1F, a resist film 20 for covering then-type TFT is formed. Then, source/drain regions of the p-type TFT areformed by ion-implanting B (boron) into the polysilicon film 13 in thep-type TFT forming region. For example, high-concentration impuritydiffusion regions 13 d are formed by ion-implanting B into thepolysilicon film 13 with a high concentration at a low energy whileusing the gate insulating film 18 and the gate electrode 19 as a mask.Also, LDD regions 13 c of the p-type TFT are formed by ion-implanting Binto the polysilicon film 13 with a low concentration at a high energywhile using the gate electrode 19 as a mask. In this manner, the n-typeTFT can be changed into the p-type TFT by implanting the p-type impurityinto the polysilicon film 13, into which the n-type impurity has beenimplanted, in larger quantity than the n-type impurity. Then, the resistfilm 20 is removed.

[0016] Then, as shown in FIG. 1G, the impurity being introduced into thepolysilicon film 13 is activated by irradiating the excimer laser ontothe polysilicon film 13.

[0017] Then, as shown in FIG. 1H, a SiO₂ film 21 and a SiN film 22 areformed sequentially as an interlayer insulating film on an overall uppersurface of the glass substrate 11. Also, an ITO (Indium-Tin Oxide) film23 is formed on the SiN film 22 and also a resist film 24 is formed onthe ITO film 23 in the pixel-electrode forming region.

[0018] Then, as shown in FIG. 1I, a pixel electrode 25 is formed byetching the ITO film 23 using the resist film 24 as a mask. Then, theresist film 24 on the pixel electrode 25 is removed.

[0019] Then, as shown in FIG. 1J, photoresist is coated on an overallupper surface of the glass substrate 11, and then a resist film 26 inwhich respective portions corresponding contact-hole forming regions areopened is formed by applying the exposing and developing processes tothe photoresist. Then, as shown in FIG. 1K, contact holes 22 a reachingthe high-concentration impurity diffusion regions 13 b, 13 d from thesurface of the SiN film 22 are formed by etching the SiN film 22 and theSiO₂ film 21 while using the resist film 26 as a mask. Then, the resistfilm 26 is removed.

[0020] Then, as shown in FIG. 1L, a metal film is formed on an overallupper surface of the glass substrate 11, and then predetermined wirings(containing the source/drain electrodes) 27 are formed by patterning themetal film by means of the photolithography method. The source region ofthe pixel TFT is connected electrically to the pixel electrode 25 viathe wiring 27. Also, the drain region of the pixel TFT is connected tothe data bus line via other wiring 27. In this manner, the TFT substrateof the liquid crystal display panel is completed.

[0021] However, the inventors of the present invention consider that theabove TFT substrate manufacturing method in the prior art contains theproblem described in the following. That is, the method in the prior artneeds a number of masking steps, which cause the increase of theproduction cost. The sub-steps such as the photoresist coating step, thepre-baking step, the exposing step, the developing step, the post-bakingstep, etc. are contained in the masking steps. Therefore, if the numberof the masking steps can be reduced, the production cost of the productcan be considerably reduced.

SUMMARY OF THE INVENTION

[0022] It is an object of the present invention to provide a thin filmtransistor device capable of reducing the number of masking steps, and amethod of manufacturing the same.

[0023] A thin film transistor device set forth in claim 1 of the presentinvention comprises a substrate; a thin film transistor formed on thesubstrate; a first insulating film formed on the substrate to cover thethin film transistor; a display electrode formed on the first insulatingfilm in a predetermined pattern; a second insulating film formed on thefirst insulating film to cover a part of the display electrode; contactholes that reach source/drain regions of the thin film transistor from asurface of the second insulating film; and a wiring formed to extendfrom an upper surface of the second insulating film to an upper surfaceof the display electrode, and connected to the source/drain regions ofthe thin film transistor via the contact holes.

[0024] In the present invention, the display electrode is formed on thefirst insulating film to cover the thin film transistor and also thisdisplay electrode is connected electrically to the thin film transistorvia the wiring that is formed on the second insulating film (protectionfilm). According to such structure, the number of manufacturing stepscan be reduced rather than the prior art.

[0025] Also, a thin film transistor device manufacturing method setforth in claim 6 of the present invention comprises the steps of forminga semiconductor film in a first conductivity type thin film transistorforming region and a second conductivity type thin film transistorforming region on a substrate respectively; forming a gate insulatingfilm and a gate electrode on the semiconductor film; forming firstconductivity type source/drain regions by introducing a firstconductivity type impurity into the semiconductor film; forming a firstinterlayer insulating film on an overall upper surface of the substrate;forming a first conductive film on the first interlayer insulating film;forming a resist film, which covers the first conductivity type thinfilm transistor forming region and a display electrode forming region,on the first conductive film; forming second conductivity typesource/drain regions by introducing a second conductivity type impurityinto the semiconductor film in the second conductivity type thin filmtransistor forming region; removing the resist film on the firstconductivity type thin film transistor forming region to leave theresist film only on the display electrode forming region; forming adisplay electrode by etching the first conductive film while using theresist film as a mask; removing the resist film from the displayelectrode forming region; forming a second interlayer insulating film onan overall upper surface of the substrate; forming contact holes thatreach source/drain regions of the thin film transistor from a surface ofthe second interlayer insulating film; forming a second conductive filmon the overall upper surface of the substrate; and processing the secondconductive film into a predetermined pattern.

[0026] Also, a thin film transistor device manufacturing method setforth in claim 10 of the present invention comprises the steps offorming a semiconductor film in a first conductivity type thin filmtransistor forming region and a second conductivity type thin filmtransistor forming region on a substrate respectively; forming a gateinsulating film and a gate electrode on the semiconductor film; formingfirst conductivity type source/drain regions by introducing a firstconductivity type impurity into the semiconductor film; forming a firstinterlayer insulating film on an overall upper surface of the substrate;forming a first conductive film on the first interlayer insulating film;forming a resist film thin in the first conductivity type thin filmtransistor forming region on the first conductive film and thick in thedisplay electrode forming region; removing the first conductive film inthe second conductivity type thin film transistor forming region whileusing the resist film as a mask; forming second conductivity typesource/drain regions by introducing a second conductivity type impurityinto the semiconductor film in the second conductivity type thin filmtransistor forming region; removing the resist film on the firstconductivity type thin film transistor forming region to leave theresist film only on the display electrode forming region; forming adisplay electrode by etching the first conductive film while using theresist film as a mask; removing the resist film from the displayelectrode forming region; forming a second interlayer insulating film onan overall upper surface of the substrate; forming contact holes thatreach source/drain regions of the thin film transistor from a surface ofthe second interlayer insulating film; forming a second conductive filmon the overall upper surface of the substrate; and processing the secondconductive film into a predetermined pattern.

[0027] In the inventions in claims 6 and 10, the display electrode isformed by utilizing the resist film that protects the first conductivitytype thin film transistor from the second conductivity type impuritywhen the second conductivity type impurity is introduced into thesemiconductor film in the second conductivity type thin film transistorforming region.

[0028] More particularly, the second conductivity type impurity isintroduced into the semiconductor film in the second conductivity typethin film transistor forming region, and then the resist film on thefirst conductivity type thin film transistor forming region is removedto leave the resist film only on the display electrode forming region.Then, the display electrode is formed by etching the first conductivefilm while using the resist film as a mask.

[0029] Accordingly, the number of masking steps can be reduced incontrast to the prior art, and thus the production cost of the thin filmtransistor device can be reduced.

[0030] Also, a thin film transistor device manufacturing method setforth in claim 13 of the present invention comprises the steps offorming a semiconductor film in a thin film transistor forming region ona substrate; forming a gate insulating film and a gate electrode on thesemiconductor film; forming an interlayer insulating film on an overallupper surface of the substrate; forming a first conductive film as adisplay electrode on the interlayer insulating film; forming contactholes, which reach the semiconductor film from a surface of the firstconductive film, by a photolithography method; forming a secondconductive film on the overall upper surface of the substrate; forming aresist film, which covers a wiring forming region and a displayelectrode forming region, on the second conductive film; etching thesecond conductive film and the first conductive film while using theresist film as a mask; removing the resist film in the display electrodeforming region to leave the resist film in the wiring forming region;and removing the second conductive film on the display electrode formingregion by an etching using the resist film as a mask.

[0031] In the present invention, the second conductive film serving asthe wiring is formed on the first conductive film serving as the displayelectrode. Then, the display electrode is formed by utilizing the maskused when the second conductive film is etched.

[0032] More particularly, the first conductive film and the secondconductive film on other regions are etched in the state that the firstconductive film and the second conductive film in the wiring formingregion and the display electrode forming region are protected by theresist film. Then, the resist film on the display electrode formingregion is removed while leaving the resist film on the wiring formingregion as it is. Then, the second conductive film formed on the firstconductive film in the display electrode forming region is removed bythe etching to expose the first conductive film.

[0033] In the present invention, the display electrode is formed in thismanner. Therefore, the number of masking steps can be reduced incontrast to the prior art, and thus the production cost of the thin filmtransistor device can be reduced.

[0034] Also, a thin film transistor device manufacturing method setforth in claim 17 of the present invention comprises the steps offorming a semiconductor film in a thin film transistor forming region ona substrate; forming a gate insulating film and a gate electrode on thesemiconductor film; forming an interlayer insulating film on an overallupper surface of the substrate; forming a first conductive film as adisplay electrode on the interlayer insulating film; forming a resistfilm, in which contact hole forming regions are opened, on the firstconductive film; forming contact holes, which reach the semiconductorfilm from a surface of the first conductive film, by executing anetching while using the resist film as a mask; removing the resist filmto leave only on the display electrode forming region; etching the firstconductive film while using the resist film remaining on the displayelectrode forming region as a mask; removing the resist film on thedisplay electrode forming region; forming a second conductive film onthe overall upper surface of the substrate; and processing the secondconductive film into a predetermined shape.

[0035] In the present invention, the display electrode is formed byutilizing the resist film used when the contact holes are formed. Moreparticularly, the first conductive film serving as the display electrodeis formed on the interlayer insulating film, then the resist film isformed on the first conductive film in a predetermined pattern, and thenthe contact holes reaching the source/drain regions of the thin filmtransistor are formed by etching the first conductive film and theinterlayer insulating film. Then, the resist film is left only in thedisplay electrode forming region but the resist film in other regions isremoved. Then, the display electrode is formed by etching the firstconductive film while using the remaining resist film as a mask.

[0036] In the present invention, the display electrode is formed in thismanner. Therefore, the number of masking steps can be reduced incontrast to the prior art, and thus the production cost of the thin filmtransistor device can be reduced.

[0037] Also, a thin film transistor device set forth in claim 21 of thepresent invention comprises a substrate; a semiconductor film formed onthe substrate and having source/drain regions of an LDD structure; afirst insulating film formed on the substrate and the semiconductorfilm; a gate electrode constructed by a first conductive film, which isformed on the first insulating film over the semiconductor film, and asecond conductive film, which is formed on the first conductive film tohave a width narrower than the first conductive film; a displayelectrode formed on the first insulating film and made of a samematerial as the first conductive film; a second insulating film formedon the first insulating film to cover the gate electrode; contact holesthat reach the semiconductor film from a surface of the secondinsulating film; and a wiring formed on the second insulating film, oneend of which is connected electrically to the semiconductor film via thecontact hole and other end of which is connected electrically to thedisplay electrode.

[0038] In the present invention, the gate electrode is composed of thefirst conductive film and the second conductive film whose width isnarrower than the first conductive film. Also, the display electrode isformed of the same material as the first conductive film. According tosuch structure, the number of manufacturing steps of the thin filmtransistor device, which has the thin film transistor of the LDDstructure, can be reduced rather than the prior art.

[0039] Also, a thin film transistor device manufacturing method setforth in claim 25 of the present invention comprises the steps offorming a semiconductor film in a thin film transistor forming region ona substrate; forming sequentially a first insulating film, a firstconductive film, and a second conductive film on an overall uppersurface of the substrate; forming a resist film in a display electrodeforming region and a gate electrode forming region on the secondconductive film; forming a display electrode and a gate electrode havinga terrace structure by applying an isotropic etching to the secondconductive film and by applying an anisotropic etching to the firstconductive film while using the resist film as a mask; removing theresist film on the display electrode forming region to leave the resistfilm on the gate electrode forming region; removing the secondconductive film remaining on the display electrode; removing the resistfilm from the gate electrode forming region; forming source/drainregions by introducing an impurity into the semiconductor film; forminga second interlayer insulating film on the overall upper surface of thesubstrate; patterning the second interlayer insulating film to exposethe display electrode and to form contact holes that reach thesemiconductor film from a surface of the second interlayer insulatingfilm; forming a third conductive film on the overall upper surface ofthe substrate; and forming a wiring, which connects electrically thesemiconductor film and the display electrode, by patterning the thirdconductive film.

[0040] In the present invention, the second conductive film is formed onthe first conductive film, and then the resist film is formed on thesecond conductive film. Then, the isotropic etching is applied to thesecond conductive film while using the resist film as a mask and alsothe anisotropic etching is applied to the first conductive film, so thatthe gate electrode having the terrace structure consisting of the firstconductive film and the second conductive film is formed and also thedisplay electrode made of the first conductive film is formed.

[0041] Then, the resist film is left in the gate electrode formingregion and the resist film is removed from the display electrode formingregion. Then, the second conductive film remaining on the displayelectrode is removed by the etching.

[0042] In the present invention, in this manner, the display electrodeand the gate electrode having the terrace structure are formed by onemasking step. Therefore, the number of masking step can be reducedrather than the prior art and also the production cost of the thin filmtransistor device can be reduced.

BRIEF DESCRIPTION OF THE DRAWINGS

[0043]FIGS. 1A to 1L are sectional views showing a method ofmanufacturing a thin film transistor device (liquid crystal displaypanel) in the prior art in order of step;

[0044]FIG. 2 is a block diagram showing a configuration of a thin filmtransistor device (transmissive liquid crystal display panel) accordingto a first embodiment of the present invention;

[0045]FIG. 3 is a sectional view showing a display portion of the thinfilm transistor device (liquid crystal display panel) according to thefirst embodiment of the present invention;

[0046]FIG. 4 is a plan view showing a TFT substrate in the displayportion of the same;

[0047]FIG. 5 is a sectional view showing a cross section of a TFTforming region of the thin film transistor device according to the firstembodiment of the present invention;

[0048]FIG. 6, FIG. 7, FIG. 8, FIG. 9, FIG. 10, FIGS. 11A and 11B, FIGS.12A and 12B, FIG. 13, FIG. 14, FIG. 15, FIG. 16, FIG. 17 are sectionalviews showing a method of manufacturing the thin film transistor deviceaccording to the first embodiment of the present invention in order ofstep;

[0049]FIGS. 18A and 18B are sectional views showing a variation of themethod of manufacturing the thin film transistor device according to thefirst embodiment of the present invention;

[0050]FIG. 19 is a circuit diagram showing a thin film transistor device(organic EL display panel) according to a second embodiment of thepresent invention;

[0051]FIG. 20 is a sectional view showing a portion, in which a drivingTFT and an organic EL element are formed, of the thin film transistordevice according to the second embodiment of the present invention;

[0052]FIGS. 21A to 21M are sectional views showing a method ofmanufacturing a thin film transistor device (liquid crystal displaypanel) according to a third embodiment of the present invention in orderof step;

[0053]FIGS. 22A to 22E are sectional views showing a method ofmanufacturing a thin film transistor device (liquid crystal displaypanel) according to a fourth embodiment of the present invention inorder of step; and

[0054]FIGS. 23A to 23I are sectional views showing a method ofmanufacturing a thin film transistor device (liquid crystal displaypanel) according to a fifth embodiment of the present invention in orderof step.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0055] Embodiments of the present invention will be explained withreference to the accompanying drawings hereinafter.

[0056] (First Embodiment)

[0057]FIG. 2 is a block diagram showing a configuration of a thin filmtransistor device (transmissive liquid crystal display panel) accordingto a first embodiment of the present invention. In the followingexample, the XGA (1024×768 pixel) mode liquid crystal display panel willbe explained hereunder.

[0058] The liquid crystal display panel according to the presentembodiment consists of a control circuit 101, a data driver 102, a gatedriver 103, and a display portion 104. The signals such as displaysignals RGB (R (red) signal, G (green) signal, and B (blue) signal), ahorizontal synchronizing signal Hsync, a vertical synchronizing signalVsync, etc. are supplied to this liquid crystal display panel from theexternal devices (not shown) such as the computer, etc. Also, a highvoltage VH (e.g., 18 V), a low voltage VL (e.g., 3.3 V or 5 V) and aground potential Vgnd are supplied to the liquid crystal display panelfrom the power supplies (not shown).

[0059] In the display portion 104, 3072 (1024×RGB) pixels are aligned inthe horizontal direction and also 768 pixels are aligned in the verticaldirection. Each pixel consists of an n-type TFT 105, and a display cell106 and a storage capacitor 107, both are connected to the sourceelectrode of the n-type TFT 105. The display cell 106 consists of a pairof electrodes and the liquid crystal sealed between these electrodes.

[0060] Also, 3072 data bus lines 108 that extend in the verticaldirection and 768 gate bus lines 109 that extend in the horizontaldirection are provided to the display portion 104. The gate electrodesof the TFTs 105 of the pixels that are aligned in the horizontaldirection are connected to the same gate bus line 109, and the drainelectrodes of the TFTs 105 of the pixels that are aligned in thevertical direction are connected to the same data bus line 108.

[0061] The control circuit 101 receives the horizontal synchronizingsignal Hsync and the vertical synchronizing signal Vsync, and thenoutputs a data start signal DSI that becomes active at a point of timewhen one horizontal synchronizing period is started, a data clock DCLKthat divides one horizontal synchronizing period into predeterminedintervals, a gate start signal GSI that becomes active at a point oftime when one vertical synchronizing period is started, and a gate clockGCLK that divides one vertical synchronizing period into predeterminedintervals.

[0062] The data driver 102 consists of a shift register 102 a, a levelshifter 102 b, and an analog switch 102 c.

[0063] The shift register 102 a has 3072 output terminals. This shiftregister 102 a is initialized by the data start signal DSI, and outputsthe low-voltage active signal from respective output terminalssequentially at the timing that is synchronized with the data clockDCLK.

[0064] The level shifter 102 b has 3072 input terminals and 3072 outputterminals. Then, the level shifter 102 b converts the low-voltage activesignal, which is output from the shift register 102 a, into the highvoltage active signal and then outputs such active signal.

[0065] The analog switch 102 c has also 3072 input terminals and 3072output terminals. Output terminals of the analog switch 102 c areconnected to corresponding data bus lines 108 respectively. The analogswitch 102 c, when receives the active signal from the level shifter 102b, outputs the display signal RGB (any one of the R signal, the Gsignal, and the B signal) to the output terminal corresponding to theinput terminal via which the active signal is input.

[0066] More particularly, the data driver 102 outputs the R signal, theG signal, and the B signal sequentially to the 3072 data bus lines 108of the display portion 104 at the timing, that is synchronized with thedata clock DCLK, within one horizontal synchronizing period.

[0067] The gate driver 103 consists of a shift register 103 a, a levelshifter 103 b, and an output buffer 103 c.

[0068] The shift register 103 a has 768 output terminals. This shiftregister 103 a is initialized by the gate start signal GSI, and outputsthe low-voltage scanning signal from respective output terminalssequentially at the timing that is synchronized with the gate clockGCLK.

[0069] The level shifter 103 b has 768 input terminals and 768 outputterminals. Then, the level shifter 103 b converts the low-voltagescanning signal, which is input from the shift register 103 a, into thehigh-voltage scanning signal and then outputs such high-voltage scanningsignal.

[0070] The output buffer 103 c has also 768 input terminals and 768output terminals. Output terminals of the output buffer 103 c areconnected to corresponding gate bus lines 109 respectively. The outputbuffer 103 c supplies the scanning signal, which is input from the levelshifter 103 b, to the gate bus line 109 via the output terminal thatcorresponds to the input terminal.

[0071] More particularly, the gate driver 103 supplies the scanningsignal sequentially to the 768 gate bus lines 109 of the display portion104 at the timing, that is synchronized with the gate clock GCLK, withinone vertical synchronizing period.

[0072] The TFT 105 of the display portion 104 is turned ON when thescanning signal is supplied to the gate bus line 109. At this time, whenthe display signal RGB (any one of the R signal, the G signal, and the Bsignal) is supplied to the data bus line 108, such display signal RGB iswritten into the display cell 106 and the storage capacitor 107. Thegradient of the liquid crystal molecules is changed by the writtendisplay signal RGB in the display cell 106, and as a result the opticaltransmittance of the display cell 106 is changed. The desired image canbe displayed by controlling the optical transmittance of the displaycell 106 every pixel.

[0073] In the present embodiment, as described above, the TFT 105 in thepixel is the n-type TFT. Also, the control circuit 101, the data driver102, and the gate driver 103 are constructed by the p-type TFTs and then-type TFTs.

[0074]FIG. 3 is a sectional view showing the display portion of theliquid crystal display panel according to the first embodiment of thepresent invention, and FIG. 4 is a plan view showing the TFT substratein the display portion of the same. In this case, although actually thestorage capacitor 107 shown in FIG. 2 is formed every pixel, theillustration and the explanation will be omitted herein.

[0075] As shown in the sectional view of FIG. 3, the liquid crystaldisplay panel of the present embodiment consists of a TFT substrate 120and a CF substrate 150 that are arranged to oppose to each other, and aliquid crystal 180 that is sealed between the TFT substrate 120 and theCF substrate 150.

[0076] The TFT substrate 120 is constructed by a glass substrate(transparent insulating substrate) 121, the data bus lines 108 that areformed on the glass substrate 121, the gate bus lines 109, the TFTs 105,and pixel electrodes (display electrodes) 128, etc. In the presentembodiment, a part of the gate bus lines 109 acts as the gate electrodesof the TFTs 105, the source electrodes of the TFTs 105 are connected tothe pixel electrodes 128, and the drain electrodes of the TFTs 105 areconnected to the data bus lines 108. Also, an alignment film 131 isformed on the pixel electrodes 128.

[0077] While, the CF substrate 150 is constructed by a glass substrate(transparent insulating substrate) 151, a black matrix 152 that isformed on the glass substrate 151, color filters 153, and a commonelectrode 154. The black matrix 152 is formed to cover regions betweenthe pixels and the TFT forming regions. Also, the color filter 153having any one color of the red color, the green color, and the bluecolor is formed every pixel. In the present embodiment, the commonelectrode 154 is formed on the color filters 153, and a surface of thecommon electrode 154 is covered with an alignment film 155.

[0078] The TFT substrate 120 and the CF substrate 150 are arranged suchthat their surfaces on which the alignment films 131, 155 are formedrespectively are opposed to each other.

[0079]FIG. 5 is a sectional view showing a cross section of the TFTforming region of the TFT 105. A structure of the TFT substrate 120 willbe explained in more detail with reference to FIG. 5 hereunder. In thiscase, illustration of the alignment film 131 is omitted from FIG. 5.

[0080] A buffer layer 122 consisting of a SiN film 122 a and a SiO₂ film122 b is formed on the glass substrate 121. A polysilicon film 123acting as the operating layer of the TFT 105 is formed on apredetermined region of the buffer layer 122.

[0081] The source/drain regions having the LDD structure are formed inthis polysilicon film 123. In other words, a pair of LDD regions(low-concentration impurity diffusion regions) 123 a are formed in thepolysilicon film 123 so as to put the channel region therebetween. Also,high-concentration impurity diffusion regions 123 b are formed on theoutside of a pair of LDD regions 123 a respectively.

[0082] A gate insulating film 124 is formed on the channel region andthe LDD regions 123 a of the polysilicon film 123. A gate electrode 125(the gate bus line 109) is formed on the gate insulating film 124. Inthe present embodiment, a width of the gate electrode 125 is formedslightly narrowly rather than a width of the gate insulating film 124.

[0083] A first interlayer insulating film 127 is formed on the bufferlayer 122 to cover the TFT 105. The pixel electrodes 128 are formed onpredetermined regions of the first interlayer insulating film 127. Also,a second interlayer insulating film (protection film) 129 is formed onthe first interlayer insulating film 127. In this case, portions thatcorrespond to the pixel electrodes 128 are opened in the secondinterlayer insulating film 129 so as to expose the pixel electrodes 128.

[0084] The data bus lines 108 and other wirings 130 are formed on thesecond interlayer insulating film 129. The data bus line 108 isconnected electrically to the drain region of the TFT 105 via the wiring130 and the contact hole provided in the interlayer insulating films127, 129. Also, the pixel electrode 128 is connected electrically to thesource region of the TFT 105 via other wiring 130 and other contacthole.

[0085]FIG. 6 to FIG. 17 are sectional views showing a method ofmanufacturing the TFT substrate having the above structure in order ofstep.

[0086] First, as shown in FIG. 6, the buffer layer 122 having thedouble-layered structure that consists of the SiN film 122 a of 50 nmthickness and the SiO₂ film 122 b of 100 nm thickness is formed bydepositing sequentially SiN and SiO₂ onto the glass substrate 121 byvirtue of the plasma CVD method. Then, an amorphous silicon film isformed on the buffer layer 122 by the plasma CVD method to have athickness of about 40 nm, and then the polysilicon film 123 is formed byapplying the laser annealing process to the amorphous silicon film.Then, the polysilicon film 123 is shaped into island shapes by thephotolithography method.

[0087] Then, as shown in FIG. 7, a SiO₂ film 141 serving as the gateinsulating film 124 is formed on an overall upper surface of the glasssubstrate 121 to have a thickness of about 100 nm. Then, an AlNd film142 serving as the gate electrode 125 is formed on the SiO₂ film 141 tohave a thickness of about 300 nm.

[0088] Then, the photoresist is coated on the AlNd film 142, and then aresist film 143 having a desired shape is formed by applying theexposing and developing processes to the photoresist.

[0089] Then, as shown in FIG. 8, the gate electrode 125 (gate bus line109) and other wiring (not shown) are formed by applying the wet etching(isotropic etching) to the AlNd film 142 while using the resist film 143as a mask. At this time, an interval between the edge of the resist film143 and the edge of the gate electrode 125 (distance in the horizontaldirection) is set to 0.3 to 2 g m by over-etching the AlNd film 142.Also, the gate insulating film 124 having the almost same width as theresist film 143 is formed by applying the dry etching (anisotropicetching) to the SiO₂ film 141 by the fluoride system gas, for example,with using the resist film 143 as a mask. Then, the resist film 143 isremoved.

[0090] In the present embodiment, in this manner, the terrace structureconsisting of the gate insulating film 124 and the gate electrode 125whose width is narrower than the gate insulating film 124 can be formedby one masking step.

[0091] In this case, in the present embodiment, as described later, theLDD regions 123 a and the high-concentration impurity diffusion regions123 b are formed by one masking step while utilizing the terracestructure consisting of the gate insulating film 124 and the gateelectrode 125. At this time, if an interval between the edge of the gateinsulating film 124 and the edge of the gate electrode 125 in thehorizontal direction is below 0.3 μm, the effect of forming the LDDregions 123 a is not sufficient. In contrast, if the interval betweenthe edge of the gate insulating film 124 and the edge of the gateelectrode 125 in the horizontal direction is in excess of 2 μm, a sizeof the thin film transistor is increased and thus the higher definitionbecomes difficult. As a result, it is preferable that the intervalbetween the edge of the gate insulating film 124 and the edge of thegate electrode 125 should be set to 0.3 to 2 μm.

[0092] Then, as shown in FIG. 9, the source/drain regions of the TFT 105are formed by ion-implanting P (phosphorous) into the polysilicon film123. For example, the high-concentration impurity diffusion regions 123b are formed by ion-implanting P into the polysilicon film 123 at theacceleration energy of 10 keV and the dosage of 1.0×10¹⁵ cm⁻² whileusing the gate electrode 125 and the gate insulating film 124 as a mask.Also, the LDD regions 123 a are formed by ion-implanting P into thepolysilicon film 123 at the acceleration energy of 70 keV and the dosageof 5.0×10¹³ cm⁻² while using the gate electrode 125 as a mask.

[0093] Then, as shown in FIG. 10, an SiO₂ film of about 60 nm thicknessis formed as the first interlayer insulating film 127 on the overallupper surface of the glass substrate 121 by the CVD method. Then, an ITOfilm 144 of about 70 nm thickness is formed on the first interlayerinsulating film 127 by the sputter method.

[0094] In this case, the material of the pixel electrode 128 is notlimited to ITO. However, in the case of the transmissive liquid crystaldisplay panel, the transparent conductive material must be employed. Asthe transparent conductive material, there is the oxide containing In,Sn, or Zn, for example.

[0095] Then, as shown in FIGS. 11A and 11B, a resist film 145 that isthick in the pixel-electrode forming region, and is thin in the n-typeTFT forming region and has openings in the portions that correspond tothe p-type TFT forming region is formed.

[0096] For example, after the photoresist film 145 is formed on theentire surface, the half-exposure is carried out by using the firstexposure mask, which shields the n-type TFT forming region and thepixel-electrode forming region from the light, and the second exposuremask, which shields the n-type TFT forming region only from the light,respectively. At this time, the magnitude of the level differencebetween the resist film in the n-type TFT forming region and the resistfilm in the pixel-electrode forming region can be changed by controllingan amount of exposure at the first time exposure and the second timeexposure. Also, if the exposure mask that shields perfectly thepixel-electrode forming region from the light and that has a number ofopening portions, whose diameter is smaller than the critical value ofthe resolution, in the portion that corresponds to the n-type TFTforming region is employed, the resist film having the thick portion andthe thin portion can be formed by one exposure.

[0097] In the present embodiment, the thickness of the resist film 145in the n-type TFT forming region is set to 1.0 μm, and the thickness ofthe resist film 145 in the pixel-electrode forming region is set to 1.5μm. However, these numerical values must be changed appropriatelyaccording to the process.

[0098] Then, the source/drain regions are formed by ion-implanting B(boron) into the polysilicon film 123 in the p-type TFT forming regionwhile protecting the pixel-electrode forming region and the n-type TFTforming region with the resist film 145. For example, thehigh-concentration impurity diffusion regions 123 d are formed byion-implanting B into the polysilicon film 123 at the accelerationenergy of 10 keV and the dosage of 2×10¹⁵ cm⁻² while using the gateelectrode 125 and the gate insulating film 124 as a mask. Also, the LDDregions 123 c are formed by ion-implanting B into the polysilicon film123 at the acceleration energy of 70 keV and the dosage of 2.0×10¹⁴ cm⁻²while using the gate electrode 125 as a mask.

[0099] In this case, as shown in FIG. 18A and FIG. 18B, after the ITOfilm 144 on the p-type TFT forming region is removed, the LDD regions123 c and the high-concentration impurity diffusion regions 123 d may beformed by implanting the boron into the polysilicon film 123.

[0100] Then, as shown in FIGS. 12A and 12B, the resist film 145 is leftonly in the pixel-electrode forming region by applying the oxygen plasmaprocess (ashing) to the resist film 145. Then, the pixel electrode 128is formed by etching the ITO film 144 while using the resist film 145 asa mask. Then, as shown in FIG. 13, the resist film 145 on the pixelelectrode 128 is removed.

[0101] Then, the impurities (P and B) introduced into the polysiliconfilm 123 are activated by applying the annealing process, the laser beamirradiating process, or the like.

[0102] Then, as shown in FIG. 14, the second interlayer insulating film129 of about 400 nm thickness is formed by depositing SiN on an overallupper surface of the glass substrate 121.

[0103] Then, as shown in FIG. 15, contact holes 129 a that reach thehigh-concentration impurity diffusion regions 123 b, 123 d from asurface of the second interlayer insulating film 129 respectively areformed by the photolithography method.

[0104] Then, as shown in FIG. 16, a conductive film 146 is formed bydepositing Ti(100 nm)/Al(200 nm)/Ti(100 nm) onto the overall uppersurface of the glass substrate 121 by virtue of the sputter method. Thisconductive film 146 is connected electrically to the high-concentrationimpurity diffusion regions 123 b, 123 d via the contact holes 129 a.

[0105] In this case, the material of the conductive film 146 is notparticularly limited. It is preferable that the laminated structureconsisting of the Al or Al alloy, which has the good conductivity, andthe refractory metal or its nitride, which has the good adhesiveness andcorrosion resistance against the silicon, should be employed. As therefractory metal suitable for the conductive film 146, there are Mo(molybdenum), Ti (titanium), Cr (chromium), Ta (tantalum), W (tungsten),etc., for example.

[0106] Then, as shown in FIG. 17, the data bus line 108 and the otherwiring 130 are formed by patterning the conductive film 146 by thephotolithography method. In the present embodiment, the source region ofthe TFT 105 is connected electrically to the pixel electrode 128 via thewiring 130, and the drain region of the TFT 105 is connectedelectrically to the data bus line 108 via other wiring 130.

[0107] The liquid crystal display panel is completed by arranging theTFT substrate, which is manufactured in this way, and the CF substrate,on which the color filters, the common electrode, etc. are formed, tooppose to each other and then sealing the liquid crystal between them.

[0108] In the present embodiment, as described above, the leveldifference is provided in the resist film 145 that covers the n-typeTFT, and then the implantation of B (boron) into the polysilicon film123 in the n-type TFT forming region at the time of forming the p-typeTFT is prevented by using this resist film 145. Then, the resist film145 is left only in the pixel-electrode forming region by applying theoxygen plasma process to the resist film 145, and then the pixelelectrode 128 is formed by etching the ITO film 144 while using theremaining resist film 145 as a mask. Accordingly, the number of stepscan be reduced in contrast to the method in the prior art. Also, in thepresent embodiment, the step of forming the contact holes is requiredonly once and thus the number of manufacturing steps can be reduced muchmore. As a result, according to the present embodiment, the productioncost of the liquid crystal display panel can be reduced considerably.

[0109] In this case, in the above embodiment, the case where the secondinsulating film is formed of SiN is explained. But the present inventionis not limited to this case, and the second insulating film may beformed of polyimide or photosensitive resin. If the second insulatingfilm is formed of the photosensitive resin, the film forming steps canbe reduced further more and thus the number of manufacturing steps canbe reduced more and more.

[0110] (Second Embodiment)

[0111]FIG. 19 is a circuit diagram showing a thin film transistor deviceaccording to a second embodiment of the present invention. The presentembodiment shows an example in which the present invention is applied toan organic EL display panel.

[0112] A plurality of data bus lines 191 and power supply lines 192,which extend in the vertical direction, and a plurality of scanning buslines 193, which extend in the horizontal direction, are formed on theglass substrate. Areas that are partitioned by the data bus lines 191,the power supply lines 192, and the scanning bus lines 193 are the pixelarea respectively.

[0113] A switching TFT 194, a driving TFT 195, a capacitor 196, and anorganic EL element (light emitting element) 197 are provided to eachpixel area respectively.

[0114] A gate of the switching TFT 194 is connected to the scanning busline 193, a source of the switching TFT 194 is connected to a gate ofthe driving TFT 195, and a drain of the switching TFT 194 is connectedto the data bus line 191. Also, the driving TFT 195 is connected betweenthe power supply lines 192 and an anode of the organic EL element 197.Then, the capacitor 196 is connected between the gate of the driving TFT195 and the power supply line 192.

[0115] In this organic EL display panel constructed in this manner, whena predetermined voltage is supplied to respective data bus lines 191 andalso a scanning signal is supplied to the scanning bus line 193 only inthe first row, the switching TFT 194 that is connected to the scanningbus line 193 in the first row is turned ON and then the voltage of thedata bus line 191 is stored in the capacitor 196.

[0116] The current according to this voltage is supplied to the organicEL element 197 via the power supply lines 192 and the driving TFT 195,and then the organic EL elements 197 in the first row emit the lightrespectively. Then, when the predetermined voltage is supplied torespective data bus lines 191 and also the scanning signal is suppliedto the scanning bus line 193 only in the second row, the organic ELelements 197 in the second row emit the light respectively.

[0117] In this manner, desired characters or images can be displayed bydriving sequentially the organic EL elements 197 in respective rows.

[0118]FIG. 20 is a sectional view showing the portion, in which thedriving TFT 195 and the organic EL element 197 are formed. In FIG. 20,the same references are affixed to the same elements as those in FIG. 5,and their detailed explanation will be omitted herein.

[0119] In the present embodiment, an organic EL layer 135 is formed onan anode (display electrode) 128 a made of ITO, and then a cathode 136made of AlLi, or the like is formed on this organic EL layer 135. Thiscathode 136 is formed commonly to respective pixels.

[0120] When the driving TFT 195 is turned ON and the voltage is appliedbetween the anode 128 a and the cathode 136, the organic EL layer 135emits the light. This light is transmitted through the anode 128 a andthe glass substrate 121 and then emitted to the outside.

[0121] In this case, in order to improve the luminous efficiency of theorganic EL layer 135, any one or two or three of an electron transferlayer, a hole transfer layer, and a contact layer (layer for improvingthe contact property) may be arranged between the anode 128 a and thecathode 136.

[0122] The TFTs of the organic EL display panel according to the presentembodiment can be manufactured in the same manner as the firstembodiment.

[0123] (Third Embodiment)

[0124]FIGS. 21A to 21M are sectional views showing a method ofmanufacturing a thin film transistor device (liquid crystal displaypanel) according to a third embodiment of the present invention in orderof step. In these Figures, for convenience of explanation, the pixel TFT(n-type TFT) is illustrated on the left side and also the p-type TFT ofthe peripheral circuit is illustrated on the right side. Actually, thepixel TFTs are formed in the display region and the peripheral circuitis formed on the outside of the display region. Also, since the n-typeTFTs of the peripheral circuit can be formed similarly to the pixelTFTs, illustration and explanation of them will be omitted herein.

[0125] First, as shown in FIG. 21A, a buffer layer 202 having adouble-layered structure consisting of a SiN film 202 a of 50 nmthickness and a SiO₂ film 202 b of 200 nm thickness is formed on a glasssubstrate (transparent insulating substrate) 201 by depositingsequentially SiN and SiO₂ by virtue of the plasma CVD method. Then, anamorphous silicon film is formed on the SiO₂ film 202 b by the plasmaCVD method to have a thickness of about 40 nm. Then, a polysilicon film203 is formed by crystallizing the amorphous silicon by using theexcimer laser. Then, photoresist films 204 each having a predeterminedshape are formed on the polysilicon film 203.

[0126] Then, as shown in FIG. 21B, the polysilicon film 203 is shapedinto the same shape as the photoresist films 204 by etching thepolysilicon film 203 while using the photoresist films 204 as a mask andusing the fluoride system gas. Then, the photoresist films 204 areremoved.

[0127] Then, as shown in FIG. 21C, a SiO₂ film 205 of about 100 nmthickness is formed as a gate insulating film on an overall uppersurface of the glass substrate 201 by the CVD method. Then, an AlNd film206 of about 300 nm thickness is formed as a gate electrode on the SiO₂film 205 by the sputter method. Then, photoresist is coated on the AlNdfilm 206, and then resist films 207 each having a desired shape areformed by applying the exposing and developing processes to thephotoresist.

[0128] Then, as shown in FIG. 21D, gate electrodes 209 is formed bywet-etching the AlNd film 206 while using the resist films 207 as amask. At this time, a width of the gate electrode 209 is formed slightlynarrowly rather than that of the resist film 207 by over-etching theAlNd film 206. Then, gate insulating films 208 each having the almostsame width as the resist film 207 are formed by applying the dry-etching(anisotropic etching) to the SiO₂ film 205 while using the resist films207 as a mask and using the fluoride system gas, for example. Then, theresist films 207 are removed.

[0129] In this manner, in the present embodiment, the terrace structureconsisting of the gate insulating film 208 and the gate electrode 209whose width is narrower than the gate insulating film 208 can be formedby one masking step.

[0130] Then, as shown in FIG. 21E, source/drain regions of the n-typeTFT are formed by ion-implanting P (phosphorus) into the polysiliconfilm 203. For example, high-concentration impurity diffusion regions 203b are formed by ion-implanting P into the polysilicon film 203 at anacceleration energy of 10 keV and a dosage of 1.0×10¹⁵ cm⁻² while usingthe gate insulating film 208 and the gate electrode 209 as a mask. Also,LDD regions 203 a of the n-type TFT are formed by ion-implanting P intothe polysilicon film 203 at an acceleration energy of 70 keV and adosage of 5.0×10¹³ cm⁻² while using the gate electrode 209 as a mask.

[0131] Then, as shown in FIG. 21F, source/drain regions of the p-typeTFT are formed by ion-implanting B (boron) into the polysilicon film 203in the p-type TFT forming region while covering only the n-type TFTforming region with a resist film 210. For example, high-concentrationimpurity diffusion regions 203 d are formed by ionimplanting B into thepolysilicon film 203 at an acceleration energy of 10 keV and a dosage of2.0×10¹⁵ cm⁻² while using the gate insulating film 208 and the gateelectrode 209 as a mask. Also, LDD regions 203 c of the p-type TFT areformed by ion-implanting B into the polysilicon film 203 at anacceleration energy of 70 keV and a dosage of 2.0×10¹⁴ cm⁻² while usingthe gate electrode 209 as a mask. In this manner, the n-type TFT can bechanged into the p-type TFT by implanting the p-type impurity into thepolysilicon film 203, into which the n-type impurity has beenintroduced, in larger quantity than the n-type impurity. Then, theresist film 210 is removed by the ashing.

[0132] Then, as shown in FIG. 21G, the impurity that has been introducedinto the polysilicon film 203 is activated by irradiating the excimerlaser onto the polysilicon film 203.

[0133] Then, as shown in FIG. 21H, a SiO₂ film 211 of 60 nm thicknessand a SiN film 212 of 370 nm thickness are formed sequentially as aninterlayer insulating film on an overall upper surface of the glasssubstrate 201 by the plasma CVD method. Also, an ITO film 213 of about70 nm thickness is formed on the SiN film 212. Then, a resist film 214having a predetermined pattern is formed on the ITO film 213.

[0134] Then, as shown in FIG. 21I, contact holes 212 a reaching thehigh-concentration impurity diffusion regions 203 b, 203 d of the n-typeTFT and the p-type TFT are formed by wet-etching the ITO film 213 whileusing the resist film 214 as a mask and then dry-etching the interlayerinsulating film (the SiN film 212 and the SiO₂ film 211) while using thefluoride system gas. Then, the resist film 214 is removed.

[0135] Then, as shown in FIG. 21J, a conductive film 215 is formed onthe overall upper surface of the glass substrate 201. This conductivefilm 215 is formed to have a structure in which a Mo film (50 nm), an Alfilm (200 nm), a MON film (90 nm), and a Mo film (15 nm), for example,are laminated from the bottom.

[0136] Then, as shown in FIG. 21K, a resist film 216 is formed on theconductive film 215 such that a thickness of such resist film is thickin the wiring forming region and thin in the pixel-electrode formingregion. Then, the data bus lines and other wirings 220 a are formed byetching the conductive film 215 while using the resist film 216 as amask. Then, the pixel electrode 218 is formed by etching the ITO film213 while using the resist film 216 as a mask. In this case, theconductive film 215 still remains on the pixel electrode 218 at thistime.

[0137] As explained in the first embodiment, the resist film 216 isformed by employing the half-exposure, in which two sheets of exposuremasks are used, or the exposure mask, in which a number of openingportions whose diameter is smaller than the critical value of theresolution are provided, for example.

[0138] Then, as shown in FIG. 21L, the resist film 216 is removed(ashing) until the conductive film 215 in the pixel-electrode formingregion is exposed.

[0139] Then, the conductive film 215 on the pixel-electrode formingregion is removed by executing the etching while using the resist film216 as a mask. Thus, as shown in FIG. 21M, the pixel electrode 218 isexposed. Also, the wirings 220 b for connecting the source region of thepixel TFT and the pixel electrode 218 are formed. Then, the resist film216 is removed. In this manner, the TFT substrate of the liquid crystaldisplay panel is completed.

[0140] In the present embodiment, since the wirings 220 a, 220 b and thepixel electrode 218 can be formed by one making step, the number ofmasking steps can be reduced rather than the conventional method. As aresult, the production cost of the liquid crystal display panel can bereduced considerably rather than the prior art.

[0141] (Fourth Embodiment)

[0142]FIGS. 22A to 22E are sectional views showing a method ofmanufacturing a thin film transistor device (liquid crystal displaypanel) according to a fourth embodiment of the present invention inorder of step.

[0143] First, as shown in FIG. 22A, like the third embodiment, theinsulating film 202 consisting of the SiN film 202 a and the SiO₂ film202 b, the polysilicon films 203, the gate insulating films 208, and thegate electrodes 209 are formed on the glass substrate 201. The n-typeLDD regions 203 a and the high-concentration impurity diffusion regions203 b are formed by introducing P (phosphorus) in the polysilicon film203 in the n-type TFT forming region. Also, the p-type LDD regions 203 cand the high-concentration impurity diffusion regions 203 d are formedby introducing B (boron) in the polysilicon film 203 in the p-type TFTforming region.

[0144] Then, as shown in FIG. 22B, the SiO₂ film 211 of 60 nm thicknessand the SiN film 212 of 370 nm thickness are formed sequentially as theinterlayer insulating film on an overall upper surface of the glasssubstrate 201 by the plasma CVD method. Then, the ITO film 213 of 70 nmthickness is formed as the transparent conductive film on the interlayerinsulating film by the sputter method, for example. Then, a resist film221 in which contact-hole forming portions are opened and whosethickness is thick in the pixel-electrode forming region and is thin inother regions is formed on the ITO film 213. As explained in the firstembodiment, such resist film 221 is formed by the method employing twosheets of exposure masks, or the method employing the exposure mask inwhich a number of opening portions whose diameter is smaller than thecritical value of the resolution are provided.

[0145] Then, as shown in FIG. 22C, contact holes 212 b are formed bywet-etching the ITO film 213 while using the resist film 221 as a maskand then dry-etching the SiN film 212 and the SiO₂ film 211 while usingthe fluoride system gas.

[0146] Then, as shown in FIG. 22D, the ashing is applied to the resistfilm 221. Thus, the resist film 221 is left only on the pixel-electrodeforming region, and also the resist film 221 in other portions isremoved. Then, a pixel electrode 228 is formed by wet-etching the ITOfilm 213 while using the remaining resist film 221 as a mask. Then, theresist film 221 on the pixel electrode 228 is removed.

[0147] Then, a conductive film having a laminated structure consistingof Ti film (100 nm)/Al film (200 nm)/Ti film (100 nm) is formed on theoverall upper surface of the glass substrate 201 by the sputter method,and then the resist film (not shown) having a predetermined pattern isformed thereon. Then, as shown in FIG. 22E, the data bus lines and otherwirings 230 are formed by etching the conductive film by means of thedry etching using the Cl (chlorine) system gas while using the resistfilm as a mask. The source region of the pixel TFT is connectedelectrically to the pixel electrode 228 via the wiring 230. Also, thedrain region of the pixel TFT is connected electrically to the data busline via other wiring 230.

[0148] The TFT substrate, which is formed in this manner, and the CFsubstrate are arranged to oppose to each other, and then the liquidcrystal is sealed between them. Accordingly, the liquid crystal displaypanel is completed.

[0149] In the present embodiment, like the third embodiment, the numberof masking steps can be reduced rather than the conventional method.Therefore, there can be achieved such advantage that the productivitycan be improved and also the production cost can be reduced.

[0150] In the above third embodiment, there is such a possibility that,when the contact holes 212 a are formed by etching the ITO film 213 andthe interlayer insulating film (the SiN film 212 and the SiO₂ film 211)(see FIG. 21I), the interlayer insulating film that is formed under theedge of the ITO film 213 serving as the pixel electrode is over-etchedand thus the conduction failure is caused in the contact holes 212 aupon forming the wiring. In contrast, in the present embodiment, afterthe contact holes 212 b are formed, the pixel electrode 228 is formed byetching the ITO film 213 and then the wiring 230 is formed. Therefore,there can be achieved the advantage such that generation of theconduction failure between the pixel electrode 228 and the source of theTFT can be avoided.

[0151] (Fifth Embodiment)

[0152]FIGS. 23A to 23I are sectional views showing a method ofmanufacturing a thin film transistor device (liquid crystal displaypanel) according to a fifth embodiment of the present invention in orderof step.

[0153] First, as shown in FIG. 23A, a buffer layer 302 having adouble-layered structure consisting of a SiN film of 50 nm thickness anda SiO₂ film of 100 nm thickness is formed by depositing sequentially SiNand SiO₂ on a glass substrate (transparent insulating substrate) 301 bythe plasma CVD method. Then, an amorphous silicon film of about 40 nmthickness is formed on the buffer layer 302 by the plasma CVD methodusing the material gas which is prepared by added H₂ into SiH₄. Then,the, silicon is crystallized by irradiating the excimer laser beam of anenergy intensity of 300 mJ/cm², for example, to form a polysilicon film303. Then, the photoresist is coated on the polysilicon film 303, andthen a resist film 304 is formed in the TFT forming region of thepolysilicon film 303 by applying the exposing and developing processesto the photoresist.

[0154] Then, as shown in FIG. 23B, the polysilicon film 303 is shapedinto the shape of the resist film 304 by dry-etching the polysiliconfilm 303 while using the resist film 304 as a mask. Then, the resistfilm 304 is removed.

[0155] Then, as shown in FIG. 23C, a SiO₂ film 304 is formed as a gateinsulating film on an overall upper surface of the glass substrate 301.Then, an ITO film 305 of 50 to 100 nm thickness is formed on the SiO₂film 304 by the sputter method. As the conditions in forming the ITOfilm, for example, the Ar gas and the O₂ gas are supplied to the chamberat a flow rate of 250 sccm (standard cc/min) and a flow rate of 0.4 sccmrespectively, the pressure in the chamber is set to 0.8 Pa, the DC poweris set to 1 W/cm², and the substrate temperature is set to 30° C.

[0156] Then, a metal film 306 having a double-layered structure which isformed by laminating a Mo film of 50 nm thickness and an AlNd film of350 nm thickness in this order is formed on the ITO film 305. Then, thephotoresist is coated on the metal film 306, and then resist films 307for covering the gate electrode, other wiring forming region, and thepixel-electrode forming region is formed by applying the exposing anddeveloping processes to the photoresist. At this time, since the methodemploying two sheets of exposure masks or the method employing theexposure mask in which a number of opening portions whose diameter issmaller than the critical value of the resolution are provided is used,a thickness of the resist film 307 in the wiring forming region is setto about 1 μm and also a thickness of the resist film 307 in thepixel-electrode forming region is set to about 0.5 μm.

[0157] Then, as shown in FIG. 23D, the metal film 306 is wet-etched bythe etchant containing the phosphoric acid as the major component whileusing the resist film 307 as a mask, and also the ITO film 305 is etchedby the dry etching (anisotropic etching). Thus, a pixel electrode 308made of the ITO film, a first gate electrode film 309 made of the ITOfilm, and a second gate electrode film 310 made of the metal film areformed. A gate electrode of the TFT is constructed by the first gateelectrode film 309 and the second gate electrode film 310.

[0158] At this time, a width of the second gate electrode film 310 isformed slightly narrowly rather than a width of the resist film 307 byover-etching the metal film 306. Since the first gate electrode film 309is formed by the dry etching (anisotropic etching), such film is formedto have the almost same width as the resist film 307. In this case, themetal film 306 is left on the pixel electrode 308 in this etching step.

[0159] In this case, in the present embodiment, as described later, theLDD regions are formed by utilizing the difference in width between thefirst gate electrode film 309 and the second gate electrode film 310. Inthis case, if an interval between the edge of the first gate electrodefilm 309 and the edge of the second gate electrode film 310 in thehorizontal direction is smaller than 0.3 μm, the effect of forming theLDD regions is reduced. In contrast, if the interval is larger than 2μm, the miniaturization of the TFT cannot be attained. As a result, itis preferable that the interval between the edge of the first gateelectrode film 309 and the edge of the second gate electrode film 310 inthe horizontal direction should be set to 0.3 to 2 μm.

[0160] Then, as shown in FIG. 23E, the oxygen plasma process (ashing) isapplied to the resist film 307. Thus, the resist film 307 on the pixelelectrode 308 is removed and also the resist film 307 is left only onthe second gate electrode film 310. Then, the metal film 306 on thepixel electrode 308 is removed by the etching. Then, the resist film 307on the second gate electrode film 310 is removed.

[0161] Then, as shown in FIG. 23F, the source/drain regions of then-type TFT are formed by introducing the n-type impurity into thepolysilicon film 303. In other words, high-concentration impuritydiffusion regions 303 b are formed by ion-implanting P (phosphorus) intothe polysilicon film 303 at a low acceleration energy with highconcentration while using the first gate electrode film 309 and thesecond gate electrode film 310 as a mask. Also, LDD regions 303 a areformed by ion-implanting P into the polysilicon film 303 at a highacceleration energy with low concentration while using the second gateelectrode film 310 as a mask.

[0162] In the case of the p-type TFT, like the first embodiment, then-type TFT is covered with the resist film, and then B (boron) isimplanted at the concentration that is twice or more that of P(phosphorus), which has already been introduced into the polysiliconfilm 303 in the p-type TFT forming region.

[0163] Then, as shown in FIG. 23G, an interlayer insulating film 311having a double-layered structure consisting of a SiO₂ film of 60 nmthickness and a SiN film of 370 nm thickness is formed on the overallupper surface of the glass substrate 301. Then, according to thephotolithography method, the interlayer insulating film 311 on the pixelelectrode 308 is removed and also contact holes 311 a reaching thehigh-concentration impurity diffusion region 303 b of the TFTrespectively are formed. The etching of the interlayer insulating film311 and the gate insulating film 304 is carried out by the dry etchingusing the CF₄/O₂ system gas, for example.

[0164] Then, as shown in FIG. 23H, a metal film 312 made of metal suchas Mo is formed on the overall upper surface of the glass substrate 301to have a thickness of about 400 nm. This metal film 312 is connectedelectrically to the high-concentration impurity diffusion regions 303 bvia the contact holes 311 a.

[0165] If the wiring resistance is regarded as important, the metal film312 may be constructed by the laminated structure consisting of Al andthe refractory metal. For example, the Mo/Al/Mo laminated structure maybe employed.

[0166] Then, as shown in FIG. 23I, wirings 313 are formed by patterningthe metal film 312 by using the photolithography method. The sourceregion of the pixel TFT is connected electrically to the pixel electrode308 via the wiring 313, and also the drain region of the pixel TFT isconnected electrically to the data bus line via other wiring 313.

[0167] The liquid crystal display panel is completed by arranging theTFT substrate, which is formed in this manner, and the CF substrate, onwhich the color filters, the common electrode, etc. are formed, tooppose mutually and then sealing the liquid crystal between them.

[0168] Also, in the present embodiment, since the pixel electrode 308,the first gate electrode film 309, and the second gate electrode film310 are formed by one masking step, the number of manufacturing stepscan be reduced in contrast to the method in the prior art. Also, in thepresent embodiment, as described above, the gate electrode is formed asthe double-layered structure consisting of the first gate electrode film309 and the second gate electrode film 310, and then the LDD regions 303a are formed by utilizing the difference in width between the first gateelectrode film 309 and the second gate electrode film 310. Accordingly,there is no necessity to pattern the gate insulating film 304 and thusthe damage of the polysilicon film 303 by the patterning of the gateinsulating film 304 can be avoided. As a result, such an advantage canbe achieved that the TFT having the good characteristic can be obtained.

[0169] In this case, in the above embodiments, the case where the n-typeTFT and the p-type TFT are formed on the substrate is explained. But thepresent invention can be applied to the case where only one of then-type TFT and the p-type TFT is formed on the substrate.

[0170] Also, the present invention is not limited to the above liquidcrystal display panel and the organic EL display panel and theirmanufacturing methods. The present invention can be applied to otherelectronic devices having the TFT and their manufacturing methods.

What is claimed is:
 1. A thin film transistor device comprising: asubstrate; a thin film transistor formed on the substrate; a firstinsulating film formed on the substrate to cover the thin filmtransistor; a display electrode formed on the first insulating film in apredetermined pattern; a second insulating film formed on the firstinsulating film to cover a part of the display electrode; contact holesthat reach source/drain regions of the thin film transistor from asurface of the second insulating film; and a wiring formed to extendfrom an upper surface of the second insulating film to an upper surfaceof the display electrode, and connected to the source/drain regions ofthe thin film transistor via the contact holes.
 2. A thin filmtransistor device according to claim 1, wherein the display electrode isa pixel electrode of a liquid crystal display panel.
 3. A thin filmtransistor device according to claim 1, wherein the display electrode isan anode of an organic EL display panel.
 4. A thin film transistordevice according to claim 1, wherein the wiring has a laminatedstructure consisting of a refractory metal film and an overlyingaluminum film or an overlying alloy film containing aluminum as a majorcomponent.
 5. A thin film transistor device according to claim 1,wherein the second insulating film is formed of polyimide orphotosensitive resin.
 6. A thin film transistor device manufacturingmethod comprising the steps of: forming a semiconductor film in a firstconductivity type thin film transistor forming region and a secondconductivity type thin film transistor forming region on a substraterespectively; forming a gate insulating film and a gate electrode on thesemiconductor film; forming first conductivity type source/drain regionsby introducing a first conductivity type impurity into the semiconductorfilm; forming a first interlayer insulating film on an overall uppersurface of the substrate; forming a first conductive film on the firstinterlayer insulating film; forming a resist film, which covers thefirst conductivity type thin film transistor forming region and adisplay electrode forming region, on the first conductive film; formingsecond conductivity type source/drain regions by introducing a secondconductivity type impurity into the semiconductor film in the secondconductivity type thin film transistor forming region; removing theresist film on the first conductivity type thin film transistor formingregion to leave the resist film only on the display electrode formingregion; forming a display electrode by etching the first conductive filmwhile using the resist film as a mask; removing the resist film from thedisplay electrode forming region; forming a second interlayer insulatingfilm on an overall upper surface of the substrate; forming contact holesthat reach source/drain regions of the thin film transistor from asurface of the second interlayer insulating film; forming a secondconductive film on the overall upper surface of the substrate; andprocessing the second conductive film into a predetermined pattern.
 7. Athin film transistor device manufacturing method according to claim 6,wherein the first conductive film is formed of transparent conductor. 8.A thin film transistor device manufacturing method according to claim 6,wherein the resist film is formed thick in the display electrode formingregion and thin in the first conductivity type thin film transistorforming region.
 9. A thin film transistor device manufacturing methodaccording to claim 6, wherein the gate electrode is formed to have awidth that is narrower than the gate insulating film, andhigh-concentration impurity diffusion regions and LDD regions are formedby implanting plural times an impurity into the semiconductor film atdifferent acceleration energies.
 10. A thin film transistor devicemanufacturing method comprising the steps of: forming a semiconductorfilm in a first conductivity type thin film transistor forming regionand a second conductivity type thin film transistor forming region on asubstrate respectively; forming a gate insulating film and a gateelectrode on the semiconductor film; forming first conductivity typesource/drain regions by introducing a first conductivity type impurityinto the semiconductor film; forming a first interlayer insulating filmon an overall upper surface of the substrate; forming a first conductivefilm on the first interlayer insulating film; forming a resist film thinin the first conductivity type thin film transistor forming region onthe first conductive film and thick in the display electrode formingregion; removing the first conductive film in the second conductivitytype thin film transistor forming region while using the resist film asa mask; forming second conductivity type source/drain regions byintroducing a second conductivity type impurity into the semiconductorfilm in the second conductivity type thin film transistor formingregion; removing the resist film on the first conductivity type thinfilm transistor forming region to leave the resist film only on thedisplay electrode forming region; forming a display electrode by etchingthe first conductive film while using the resist film as a mask;removing the resist film from the display electrode forming region;forming a second interlayer insulating film on an overall upper surfaceof the substrate; forming contact holes that reach source/drain regionsof the thin film transistor from a surface of the second interlayerinsulating film; forming a second conductive film on the overall uppersurface of the substrate; and processing the second conductive film intoa predetermined pattern.
 11. A thin film transistor device manufacturingmethod according to claim 10, wherein the first conductive film isformed of transparent conductor.
 12. A thin film transistor devicemanufacturing method according to claim 10, wherein the gate electrodeis formed to have a width that is narrower than the gate insulatingfilm, and high-concentration impurity diffusion regions and LDD regionsare formed by implanting plural times an impurity into the semiconductorfilm at different acceleration energies.
 13. A thin film transistordevice manufacturing method comprising the steps of: forming asemiconductor film in a thin film transistor forming region on asubstrate; forming a gate insulating film and a gate electrode on thesemiconductor film; forming an interlayer insulating film on an overallupper surface of the substrate; forming a first conductive film as adisplay electrode on the interlayer insulating film; forming contactholes, which reach the semiconductor film from a surface of the firstconductive film, by a photolithography method; forming a secondconductive film on the overall upper surface of the substrate; forming aresist film, which covers a wiring forming region and a displayelectrode forming region, on the second conductive film; etching thesecond conductive film and the first conductive film while using theresist film as a mask; removing the resist film in the display electrodeforming region to leave the resist film in the wiring forming region;and removing the second conductive film on the display electrode formingregion by an etching using the resist film as a mask.
 14. A thin filmtransistor device manufacturing method according to claim 13, whereinthe first conductive film is formed of transparent conductor.
 15. A thinfilm transistor device manufacturing method according to claim 13,wherein the resist film is formed thick in the wiring forming region andthin in the display electrode forming region.
 16. A thin film transistordevice manufacturing method according to claim 13, wherein the gateelectrode is formed to have a width that is narrower than the gateinsulating film, and high-concentration impurity diffusion regions andLDD regions are formed by implanting plural times an impurity into thesemiconductor film at different acceleration energies.
 17. A thin filmtransistor device manufacturing method comprising the steps of: forminga semiconductor film in a thin film transistor forming region on asubstrate; forming a gate insulating film and a gate electrode on thesemiconductor film; forming an interlayer insulating film on an overallupper surface of the substrate; forming a first conductive film as adisplay electrode on the interlayer insulating film; forming a resistfilm, in which contact hole forming regions are opened, on the firstconductive film; forming contact holes, which reach the semiconductorfilm from a surface of the first conductive film, by executing anetching while using the resist film as a mask; removing the resist filmto leave only on the display electrode forming region; etching the firstconductive film while using the resist film remaining on the displayelectrode forming region as a mask; removing the resist film on thedisplay electrode forming region; forming a second conductive film onthe overall upper surface of the substrate; and processing the secondconductive film into a predetermined shape.
 18. A thin film transistordevice manufacturing method according to claim 17, wherein the firstconductive film is formed of transparent conductor.
 19. A thin filmtransistor device manufacturing method according to claim 17, whereinthe resist film is formed thick in the display electrode forming regionand thin in other regions.
 20. A thin film transistor devicemanufacturing method according to claim 17, wherein the gate electrodeis formed to have a width that is narrower than the gate insulatingfilm, and high-concentration impurity diffusion regions and LDD regionsare formed by implanting plural times an impurity into the semiconductorfilm at different acceleration energies.
 21. A thin film transistordevice comprising: a substrate; a semiconductor film formed on thesubstrate and having source/drain regions of an LDD structure; a firstinsulating film formed on the substrate and the semiconductor film; agate electrode constructed by a first conductive film, which is formedon the first insulating film over the semiconductor film, and a secondconductive film, which is formed on the first conductive film to have awidth narrower than the first conductive film; a display electrodeformed on the first insulating film and made of a same material as thefirst conductive film; a second insulating film formed on the firstinsulating film to cover the gate electrode; contact holes that reachthe semiconductor film from a surface of the second insulating film; anda wiring formed on the second insulating film, one end of which isconnected electrically to the semiconductor film via the contact holeand other end of which is connected electrically to the displayelectrode.
 22. A thin film transistor device according to claim 21,wherein the LDD structure of the semiconductor film is formed byutilizing a difference in width between the first conductive film andthe second conductive film.
 23. A thin film transistor device accordingto claim 21, wherein the first conductive film is formed of transparentconductor.
 24. A thin film transistor device according to claim 21,wherein the wiring has a laminated structure consisting of a refractorymetal film and an aluminum film or an aluminum alloy film.
 25. A thinfilm transistor device manufacturing method comprising the steps of:forming a semiconductor film in a thin film transistor forming region ona substrate; forming sequentially a first insulating film, a firstconductive film, and a second conductive film on an overall uppersurface of the substrate; forming a resist film in a display electrodeforming region and a gate electrode forming region on the secondconductive film; forming a display electrode and a gate electrode havinga terrace structure by applying an isotropic etching to the secondconductive film and by applying an anisotropic etching to the firstconductive film while using the resist film as a mask; removing theresist film on the display electrode forming region to leave the resistfilm on the gate electrode forming region; removing the secondconductive film remaining on the display electrode; removing the resistfilm from the gate electrode forming region; forming source/drainregions by introducing an impurity into the semiconductor film; forminga second interlayer insulating film on the overall upper surface of thesubstrate; patterning the second interlayer insulating film to exposethe display electrode and to form contact holes that reach thesemiconductor film from a surface of the second interlayer insulatingfilm; forming a third conductive film on the overall upper surface ofthe substrate; and forming a wiring, which connects electrically thesemiconductor film and the display electrode, by patterning the thirdconductive film.
 26. A thin film transistor device manufacturing methodaccording to claim 25, wherein the second conductive film is formed oftransparent conductor.
 27. A thin film transistor device manufacturingmethod according to claim 25, wherein the resist film is formed thick inthe display electrode forming region and thin in the gate electrodeforming region.
 28. A thin film transistor device manufacturing methodaccording to claim 25, wherein, in the step of introducing the impurityinto the semiconductor film, high-concentration impurity diffusionregions and LDD regions are formed by implanting plural times theimpurity into the semiconductor film at different acceleration energies.